Lunar Contour Crafting - A Novel Technique for ISRU-Based Habitat Development

Abstract

and Michael R. Fiske5Morgan Research Colporation, Huntsville. AL, 35805 As the nation prepares to return to the hfoon, it is apparent that the viability of long duration visits with appropriate radiation shieldingkrew protection, hinges on the development of Lunar structures, preferably in advance of a manned landing, and preferably utilizing in-situ resources. Contour Crafting is a KSC-patented technique for automated development of terrestrial concrete-based structures. The process is relatively fast, completely automated, and supports the incorporation of various infrastructure elements such as plumbing and electrical wiring. This paper will present a conceptual design of a Lunar Contour Crafting system designed to autonomously fabricate integrated structures on the Lunar surface using high-strength concrete based on Lunar regolith, including glass reinforcement rods or fibers fabricated from melted regolith. Design concepts will be presented, as well as results of initial tests aimed at concrete and glass production using Lunar regolith simulant. Key issues and concerns will be presented, along with design concepts for an LCC testbed to be developed at MSFC's Prototype Development Laboratory (PDL).

Additive manufacturing of physical assets by using ceramic multicomponent extra-terrestrial materials

“…In order for this step of human colonisation to become a reality, engineers back on earth are assigned the highly challenging task in finding efficient and cost-effective ways to build structures that will be able to support life and scientific activity whilst resisting Martian/Lunar environmental threats such as micro-meteoroid impacts, solar and cosmic radiation, intense temperature loads, etc. Numerous studies are available in the literature proposing and engineering ways in fabricating habitats by either dwelling caves underneath the surface or via the concept of In-Site Resource Utilisation (ISRU) to use indigenous materials, readily available onsite to build such habitat structures (8)(9)(10).…”

Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints

“…Investment casting molds and cores have been printed in sand [343] and large structures have been printed in clay and concrete [171] [173]. Research to print Lunar and Martian habitats using locally available materials such as lunar regolith is also underway [172]. Various AM processes have been used to print edible items such as chocolate, sugar, frosting, pasta, spreads, cheese, scallop puree, ground beef, egg whites, insect powders, and an entire pizza.…”

Assessing extraterrestrial regolith material simulants for in-situ resource utilisation based 3D printing

“…the Moon, Mars etc. ), that would function autonomously and utilise indigenous materials as feedstock [8][9][10][11]. Previous studies have demonstrated that the application of a Powder Bed Fusion 3D printing process can manufacture structures/components from multi component ceramics that closely simulate Lunar and Martian regolith [12,13].…”